Woven diaper



Nov. 15, 1966 D. w. KERN 3,2 46

WOVEN DIAPER Filed April 2, 1965 DALE W. KERN BYMiMJ,

ATTORNEYS United States Patent 3,285,246 WOVEN DIAPER Dale W. Kern, Ware Shoals, S.C., assignor to Riegel Textile Corporation, a corporation of Delaware File-d Apr. 2, 11965, Ser. No. 445,019 4 Claims. (Cl. 128-284) This invention relates to a woven diaper and more particularly to a single ply woven diaper which has the absorbency and wear characteristics of a multi-ply woven diaper and which may be folded and sewn to form a prefolded woven diaper.

Heretofore, woven diapers have usually been in the form of a multi-ply, relatively light and open gauze material or single ply materials utilizing a birdseye weave or flannel construction. The gauze diapers are often folded and sewn by the diaper manufacturers to provide a prefolded diaper which is ready for use by diaper services and consumers. While the multi-ply gauze diapers are somewhat more expensive to construct initially than the single ply birdseye or flannel diapers, they may be folded and sewn to form a prefolded diaper which has superior absorbency characteristics.

It has not heretofore been considered possible to obtain a single ply diaper, adapted to be folded and sewn to form a prefolded diaper, which could be constructed at a lower cost than the multi-ply gauze diapers and the single ply birdseye and flannel diapers, yet have the same or superior absorbency and wear characteristics as the multi-ply gauze diaper.

It is, therefore, the object of this invention to provide a single ply woven diaper, adapted to be folded and sewn vto form a prefolded diaper, which has at least the same absorbency and wear characteristics of a multi-ply diaper and which may be constructed at a lower cost than a multiply diaper.

It has been found by this invention that this object may be accomplished by providing a woven diaper which has warp yarns and filling yarns therein and in which the filling yarns are much heavier and bulkier than the warp yarns to thereby reduce the picks per inch required to weave the diaper resulting in a reduction in the cost of the diaper. In utilizing filling yarns which are much heavier and bulkier than warp yarns it is preferable to use filling yarns which also have a lower twist multiple than the warp yarns to thereby increase the bulk of the filling yarn which further reduces the picks per inch required to weave the diaper material. It has also been found that if heavy and bulky filling yarns are used, that the ends per inch of the warp yarns may be reduced resulting in a further savings in the cost of manufacture. It has been further found by this invention that if this resulting diaper material is napped or brushed slightly on each side, that a material is obtained which has still greater absorbency and bulk. The resulting diaper material constructed according to this invention has the surprising result of wear characteristics comparable to the multi-ply gauze diaper material.

The thus formed diaper may be folded and sewn in a special manner, such as disclosed in our copending application Serial No. 334,694, filed December 31, 1963, to obtain a prefolded diaper in which the selvage edges of the unfolded diaper form the longitudinal edges of the prefolded diaper to resist wear therealong and in which a prefolded diaper of conventional size may be formed, having a wider than normal center panel, from a considerably smaller unfolded diaper than has heretofore been required.

Further features of this invention will be understood from the following description taken in conjunction with the accompanying drawings in which:

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FIGURE 1 is a perspective view of an unfolded diaper constructed according to this invention and cut from a continuous web of material;

FIGURE 2 is a cross-sectional view of the unfolded diaper of FIGURE 1 taken substantially along the line 2-2 of FIGURE 1;

FIGURE 3 is a perspective view of a prefolded and sewn diaper formed from the unfolded diaper of FIG- URE 1;

FIGURE 4 is a cross-sectional view of the prefolded and sewn diaper of FIGURE 3 taken substantially along the line 4-4 of FIGURE 3; and

FIGURE 5 is a microscopic view of the diaper material forming the unfolded diaper of FIGURE 1 and the prefolded diaper of FIGURE 3 illustrating the heavy filling yarns and the napped surface and taken substantially within the circle 5 of FIGURE 3.

Referring now to the drawings, there is shown an unfolded diaper 10 which has been cut from a continuous web of diaper material along cut edges 11. This unfolded diaper 10 comprises a single ply of material woven in a plain weave pattern with filling yarns 12 and warp yarns 13. The diaper 10 also includes selvages 14 which are conventionally constructed heavier and denser than the remaining portions thereof to prevent raveling.

In weaving the diaper 10, the yarns utilized as the filling yarns 12 are much heavier and bulkier than the warp yarns 13 and have a lower twist multiple than these warp yarns. The use of these heavier and bulkier filling yarns will reduce the picks per inch of the filling yarns and the ends per inch of the warp yarns required for the unfolded diaper 10 and thereby reduce the cost of weaving the diaper 10.

It has been found that a satisfactory diaper construction of this type may be obtained when the warp yarns have a cotton count of approximately 400-800 percent that of the filling yarns and the filling yarns have a twist multiple of approximately percent that of the warp yarns.

For example, if conventional warp yarns are utilized which have a cotton count of 30 and a twist multiple of 4.5 and heavier, bulkier filling yarns are utilized which have a cotton count of 5 and a twist multiple of 3.4, then an unfolded diaper according to this invention may be constructed with 26 picks per inch for the filling yarns and 40 ends per inch for the warp yarns.

For comparison, in a comparable weight conventional gauze diaper, if warp yarns are utilized which have a cotton count of 25 and a twist multiple of 4.1 and filling yarns are utilized which have a cotton count of 33 and a twist multipel of 4.1, then it would require 58 picks per inch for the filling yarns and ends per inch for the warp yarns to construct the diaper.

For comparison, in a comparable weight conventional birdseye diaper, if warp yarns are utilized which have a cotton count of 30 and a twist multiple of 4.5 and filling yarns are utilized which have a cotton count of 12 and a twist multiple of 3.5, then it would require 46 picks per inch for the filling yarns and 60 ends per inch for the warp yarns to construct the diaper.

Thus, it may be seen that the use of the heavier and bulkier filling yarns with a lower twist multiple will result in a reduction in the required number of picks per inch for the filling yarns from 58 for the gauze diaper and 46 for the birdseye diaper to 26 for the diaper of this invention. Also, the required ends per inch for the warp yarns are reduced from 80 for the gauze diaper and 60 for the birdseye to 40 for the diaper of this invention. This will result in a substantial saving in the cost of construction of the diaper of this invention of approximately 13 percent as compared to the gauze diaper and approximately 25 percent as compared to the birdseye diaper.

The unfolded diaper 10, constructed as described above, may be napped or brushed slightly on each side thereof to provide additional absorbency and bulk.

The unfolded diaper 10 may be folded and sewn to form the prefolded and sewn diaper 20, shown in FIG- URES 3 and 4. It is axiomatic that the strongest portion of the unfolded diaper 10 will be the selvage edges 14 and, therefore, the diaper 10 is folded in the novel manner with a multiple reverse fold, as set forth in our above identified copending application, so that the selvage edges 14 will form the longitudinal edges of the prefolded and sewn diaper 20 to resist wear therealong. This novel fold will also allow the formation of a prefolded diaper 20 of conventionl size, having a wider than normal center panel, from considerably smaller or narrower diaper 10 than has heretofore been required.

This prefolded and sewn diaper 20 is formed from the folded diaper 10 by first folding the unfolded diaper 10 back upon itself in a reverse fold along a first fold line 21 which is spaced from and parallel to the left selvage edge 14, as viewed in FIGURES 3 and 4. The diaper material extending from the left selvage edge 14 to the first fold line 21 defines a first single ply layer and the material folded back upon itself from the first fold line 21 defines a second single ply layer extending therefrom toward the left selvage edge 14. This second layer is then folded back upon itself to form a second reverse fold along a second fold line 22 parallel to the first fold line 21 and extending inwardly from the left selvage edge 14 between the selvage 14 and the first fold line 21. The last mentioned folded-over material forms a third single ply layer extending to the right from the second fold line 22 past the first fold line 21 to the right selvage edge 14, as viewed in FIGURES 3 and 4.

In the thus folded diaper, the three folded-over single ply layers form a center panel 25 located between fold lines 21 and 22. The portion of the first single ply layer extending from the left selvage edge 14 to the second fold line 22 forms a first side panel 26 and the portion of the third single ply layer extending from the right selvage 14 to the first fold line 21 forms a second side panel 27. These panels 25, 26 and 27 and the prefolded diaper 20 now have a longer dimension corresponding to the shorter dimension of the unfolded diaper 10 and the side panels 26 and 27 extend transversely outwardly from the center panel 25. This prefolded diaper 20 is permanently secured together by lines of stitching 28 parallel with and closely adjacent to the first and second fold lines 21 and 22. The cut edges 11 may be provided with overedge stitching 29 to prevent any raveling at these out edges.

In utilizing this novel fold, an unfolded diaper 10 of approximately 28 inches from selvage to selvage may be used to form a prefolded diaper 20 of approximately 14 inches from selvage to selvage and having a widened center panel 25 of approximately 6 /2 inches in width. For comparison, with the use of conventional folds, it would require an unfolded diaper of approximately 40 inches from selvage to selvage to form the same size prefolded diaper and the center panel would normally be approximately /2 inches wide.

Depending upon the size of the infant, this prefolded and sewn diaper 20 may have to be additionally folded or not to form a front portion, rear portion, crotch portion and leg apertures when placed in position on the wearer in the normal manner of diapering infants.

From the description, it may be seen that a diaper, either unfolded or prefolded and sewn, may be provided which utilizes a single ply of material, which can be constructed cheaper than conventional multi-ply diapers or conventional single ply diapers, and which will have the same or superior absorbency and wear characteristics as these conventional diapers.

This invention has been described in detail above for purposes of illustration only and it is not intended to be limited by this description or otherwise except as defined in the appended claims.

What is claimed is:

1. A prefolded diaper formed from an unfolded diaper having selvage edges and cut edges, said unfolded diaper comprising a single ply having Warp yarns and filling yarns therein, said warp yarns having a cotton count of approximately 400800% of the cotton count of said filling yarns and said filling yarns having a twist multiple of approxiamtely 75% of the twist multiple of said warp yarns whereby said filling yarns are heavier and bulkier than said warp yarns to reduce the required number of picks per inch for said filling yarns and the required number of ends per inch for said warp yarns in said diaper to reduce the cost thereof, said unfolded diaper having napped surfaces on each side thereof to increase the absorbency and bulk of said prefolded diaper, said prefolded diaper being folded to form an absorbent center panel comprising a plurality of layers of said unfolded diaper and side panels comprising a single layer of said unfolded diaper and extending transversely outwardly from said center panel and having outer longitudinal edges, said prefolded diaper being permanently secured together in the prefolded condition, and said prefolded diaper being folded with a multiple reverse fold so that said outer longitudinal edges thereof are formed by said selvage edges to resist wear along said outer longitudinal edges and so that a conventional size prefolded diaper with a wider than normal center panel may be formed from a smaller than normal unfolded diaper.

2. A woven diaper constructed to use less picks per inch and ends per inch when compared to conventional diapers for reducing-the cost thereof and adapted to be folded to form a front portion, rear portion, crotch portion and leg apertures when placed in position on the wearer, said diaper comprising a single plain weave ply having warp yarns and filling yarns therein, all of said warp yarns having a cotton count of approximately 400- 800% of the cotton count of all of said filling yarns and said filling yarns having a twist multiple of approximately 75% of the twist multiple of said warp yarns whereby said filling yarns are heavier and bulkier than said warp yarns to reduce the required picks per inch for said filling yarns and the required ends per inch for said warp yarns when compared with conventional diapers yet retaining the absorbency and wear characteristics of conventional diapers.

3. A woven diaper, as set forth in claim 2, which has napped surfaces on each side thereof to increase the absorbency and bulk of said diaper.

4. A prefolded diaper formed from an unfolded diaper having selvage edges and cut edges, said unfolded diaper comprising a single ply having warp yarns and filling yarns therein, said warp yarns having a cotton count of approximately 400800% of the cotton count of said filling yarns and said filling yarns having a twist multiple of approximately 75% of the twist multiple of said warp yarns whereby said filling yarns are heavier and bulkier than said warp yarns to reduce the required number of picks per inch for said filling yarns and the required ends per inch for said Warp yarns in said diaper to reduce the cost thereof, said prefolded diaper being folded to form an absorbent center panel comprising a plurality of layers of said unfolded diaper and side panels comprising a single layer of said unfolded diaper and extending transversely outwardly from said center panel and having outer longitudinal edges, said prefolded diaper being permanently secured together in the prefolded condition, and said prefolded diaper being folded with a multiple reverse fold so that said outer longitudinal edges thereof are formed by said selvage edges to reduce wear along said outer longitudinal edges and so that a conventional-size prefolded 5 6 diaper with a wider-than-norrnal center panel may be FOREIGN PATENTS formed from a smaller-than-normal unfolded diaper. 909,949 11/1962 Great Britain.

OTHER REFERENCES References Cited by the Examiner 5 Staple Cotton F-abnc, John Hoye, McGraw-Hill, New

UNITED STATES PATENTS York, 1942 2,731,045 1/1956 Owen 139-426 A. Przmary Exammer.

3,030 95 4 19 2 Nichols 123 234 C. F. ROSENBAUM, Assistant Examiner. 

1. A PREFOLDED DIAPER FORMED FROM AN UNFOLDED DIAPER HAVING SELVAGE EDGES AND CUT EDGES, SAID UNFOLDED DIAPER COMPRISING A SINGLE PLY HAVING WARP YARNS AND FILLING YARNS THEREIN, SAID WARP YARNS HAVING A COTTON COUNT OF APPROXIMATELY 400-800% OF THE COTTON COUNT OF SAID FILLING YARNS AND SAID FILLING YARNS HAVING A TWIST MULTIPLE OF APPROXIMATELY 75% OF THE TWIST MULTIPLE OF SAID WARP YARNS WHEREBY SAID FILLING YARNS ARE HEAVIER AND BULKIER THAN SAID WARP YARNS TO REDUCE THE REQUIRED NUMBER OF PICKS PER INCH FOR SAID FILLING YARNS AND THE REQUIRED NUMBER OF ENDS PER INCH FOR SIDE WARP YARNS IN SAID DIAPER TO REDUCE THE COST THEREOF, SAID UNFOLDED DIAPER HAVING NAPPED SURFACES ON EACH SIDE THEREOF TO INCREASE THE ABSORBENCY AND BULK OF SAID PREFOLDED DIAPER, SAID PREFOLDED DIAPER BEING FOLDED TO FORM AN ABSORBENT CENTER PANEL COMPRISING A PLURALITY OF LAYERS OF SAID UNFOLDED DIAPER AND SIDE PANELS COMPRISING A SINGLE LAYER OF SAID UNFOLDED DIAPER AND EXTENDING TRANSVERSELY OUTWARDLY FROMSAID CENTER PANEL AND HAVING OUTER LONGITUDINAL EDGES, SAID PREFOLDED DIAPER BEING PERMANENTLY SECURED TOGETHER IN THE PREFOLDED CONDITION, AND SAID PREFOLDED DIAPER BEING FOLDED WITH A MULTIPLE REVERSE FOLD SO THAT SAID OUTER LONGITUDINAL EDGES THEREOF ARE FORMED BY SAID SELVAGE EDGES TO RESIST WEAR ALONG SAID OUTER LONGITUDINAL EDGES AND SO THAT A CONVENTIONAL SIZE PREFOLDED DIAPER WITH A WIDER THAN NORMAL CENTER PANEL MAY BE FORMED FROM A SMALLER THAN NORMAL UNFOLDED DIAPER. 